Drilling Tool

ABSTRACT

Methods of forming a drill bit or boring tool having a cutting edge that includes a pair of generally smooth curvilinear shaped portions that are positioned near the radial outer portions of the cutting edge and connected to one another by a pair of generally linear portions that traverse a longitudinal centerline of the tool.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application and claims priority to U.S.Non-Provisional patent application Ser. No. 13/477,744 filed on May 22,2012 titled “Drilling Tool”, which claims priority to U.S. ProvisionalPatent Application Ser. No. 61/489,069 filed on May 23, 2011 titled“Drill Having Wave Form Cut Point” and the disclosure of which isexpressly incorporated herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to cutting and boring tools and,more specifically, an improved cutting tip shape for improving tool lifeand/or cutting performance,

2. Discussion of the Related Art

Virtually every industry requires the periodic piercing of variousmaterials to form openings for any number of reasons includingventilation or fluid circulation, for acceptance or cooperation withother structures, and/or for passage of other structures such asfasteners. Understandably, these are only but of few of the reasonscommonly encountered and associated with perforating a particularmaterial or structure. It is further appreciated that, as beingapplicable across a plethora of industries, such motivations areapplicable to various types and shapes of the respective material.

A plethora of drill bits are known for various applications and for usewith virtually any material. Those skilled in the art will readilyappreciate that every drill has a useable life wherein the drill willadequately cut the underlying material, will negligibly deform thematerial during the drilling operation, and maintain a suitableoperating temperature during the drilling process. Those skilled in theart equally appreciate that a worn or consumed boring or drilling toolwill require excessive downward force for subsequent drilling operation,requires increased torsional loading to effectuate the drillingoperation, can create unacceptable mushrooming or blowout of thesubstrate material near the hole site, and/or can generate unacceptabletemperatures that can detrimental effect both the tool, the material ofthe substrate, and the quality of the perforation.

After an initial use period, some users attempt to extend the usablelift of a worn tool by restoring the shape of the cutting tip to asharpened edge. Periodically, some worn tools can be re-sharpened insuch a manner but it is readily appreciated that such processing of thetooling achieves only a very limited usability of the tooling beyond theoriginal projected usable life of the tool, can detrimentally affect theoriginal equipment manufacturer (OEM) finishing of the cutting tool, andcan generate undesirable heat in the tool and particularly the cuttingedge during the sharpening operation. Commonly, such post manufactureprocesses can only remotely approximate the quality of the initial OEMcutting tip shape and configuration. Periodically, such attempts caneven detract from the performance of the tooling due in part to thereconfiguration and/or heat treatment of the cutting tip. Additionally,such processes are susceptible to individualization of the tooling as afunction of the skill of the respective user or, technician attemptingthe sharpening process and can detrimentally affect the repeatabilityassociated with hole formation during subsequent use, of the respectivetooling. Accordingly, such processes provide only limited, if any,extension of the usable life of the respective tool.

It is further appreciated that the profitability and efficiency of anyindustry that relies heavily upon drilling operations can besubstantially affected by drilling tools that degrade and/or are tooquickly consumed during normal use. Tooling that is consumed too quicklyduring normal use results in increased operator time associated withtooling changes, increases manufacturing costs due to the increasedconsumption of tooling, can increase the wear associated with operationof the tool driving devices, decreases part throughput and processtimes, and negatively contributes to the overall efficiency of partproduction and manufacture.

It would therefore, rather than providing yet another post manufacturecutting tool sharpening tool or system, be desirable to provide a boringtool such as a drill bit that is configured to better withstand theforces associated with drilling operations and to do so in a manner thatdoes not substantially increase the cost associated with production ofsuch tooling. It would also be desirable to provide a drill bit with animproved operating life and which does not materially affect the qualityof the substrate proximate a hole site.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a boring tool that overcomes one or moreof the drawbacks discussed above. A first aspect of the inventiondiscloses a drill bit or boring tool having cutting edge that includes apair of generally smooth curvilinear shaped portions that are positionednear the radial outer portions of the cutting edge and connected to oneanother by a pair of generally linear portions that traverse thelongitudinal centerline of the tool. A drill bit or boring tool having acutting edge or cutting tip having such a shape has been shown toprovide improved usable tool life while also reducing the undesirableeffects of tear out, mushrooming, and heating of the work materialthroughout the useable life of the boring tool.

Another aspect of the invention discloses a drill bit having a shaftthat extends along a longitudinal axis. The shaft includes a shank thatis engageable with a drive tool at one end of the shaft and a cuttingtip at an opposite end of the shaft. The cutting tip further comprisesat least two cutting edges that each extend in an outward radialdirection between the longitudinal axis of the shaft and an outercircumference of the shaft Each cutting edge is tapered toward the shankas the cutting edge extends in an outward radial direction from thelongitudinal axis. Each cutting edge includes at least one deviationfrom a linear shape. The at least one deviation has a curvilinear shapethat extends between the linear portion of the respective cutting edgeand an outer radial edge of the shaft.

Another aspect of the invention discloses a method of forming a boringtool. An elongate body is provided that extends along a longitudinalaxis. The elongate body includes a first end that is configured tocooperate with a drive tool and a cutting point that is formed at asecond end of the body opposite the first end. A first linear portionand a second linear portion are formed along a distal edge of thecutting point. The first linear portion and the second linear portionare formed on opposite sides of the longitudinal axis of the elongatebody. A first curvilinear contour and a second curvilinear contour areformed in the distal edge of the cutting point. Each curvilinear contouris offset in a radial direction from the longitudinal axis of theelongated body and located radially outboard of the respective adjacentlinear portion such that the only non-tangential discontinuity of thecutting point occurs at a transition between the first linear portionand the second linear portion at the intersection of the longitudinalaxis.

A further aspect of the invention discloses a drill bit having anelongated body that extends between a tool end and a work end. A cuttingtip is formed at the work end of the drill bit. A first linear portionand a second linear portion are each formed on the cutting tip andintersect one another proximate a centerline of the elongated body. Eachlinear portion extends laterally across the cutting tip and is pitchedtoward the tool end of the elongate body as each respective linearportion extends in an outward radial direction from the centerline. Agroove portion is formed on each opposite lateral side of the cuttingtip. Each groove portion is located radially outboard of an adjacent oneof the first linear portion and the second linear portion and extendslaterally across the elongated body. Each groove portion is also pitchedtoward the shank end of the elongate body and terminates short of acircumferential radius of the elongated body. Each groove portion andcorresponding respective linear portion form a continuous tangentialshape that extends the entire length of the cutting tip on each oppositeside of the centerline.

These and various other aspects, features, and advantages of the presentinvention will be made apparent from the following detailed descriptionand the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A dear conception of the advantages and features constituting thepresent invention, and of the construction and operation of typicalmechanisms provided with the present invention, will become more readilyapparent by referring to the exemplary, and therefore non-limiting,embodiments illustrated in the drawings accompanying and forming a partof this specification, wherein like reference numerals designate thesame elements in the several views, and in which:

FIG. 1 is a side elevation view of a drill bit accordingly to oneembodiment of the present invention;

FIG. 2 is top plan view of the drill bit shown in FIG. 1;

FIG. 3 is a detailed elevation view of a portion of a work tip of thedrill bit shown in FIG. 1;

FIG. 4 is a view similar to FIG. 1 of a drill bit according to anotherembodiment of the invention;

FIG. 5 is a top plan view of the drill bit shown in FIGS. 4; and

FIG. 6 is a detailed elevation view of a portion of a work tip of thedrill bit shown in FIG. 1.

In describing the preferred embodiments of the invention which areillustrated in the drawings, specific terminology is resorted to for thesake of clarity. However, it is not intended that the invention belimited to the specific terms so selected and it is to be understoodthat each specific term includes all technical equivalents which operatein a similar manner to accomplish a similar purpose. For example, theword connected or terms similar thereto can often be used. They are notlimited to direct connection but include connection through otherelements where such connection is recognized as being equivalent bythose skilled in the art.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1-3 show a boring tool, a drilling tool, drill bit or simply a bit10 having a pair of cutting edges 12, when considered with respect to aradial direction and relative to the longitudinal center axis of bit 10,according to a first embodiment of the present invention. As shown inFIG. 1, bit 10 includes an elongate body 14 generally defined as a shaft16 that extends between a shank or tool end 18 and a tip, cutting tip,work tip, or work end 20. Tool end 18 is generally understood as thatportion of bit 10 constructed to be chucked or otherwise engaged with adriving tool, such as a chuck, a drill, a mandrel, or other rotatabledriving element to effectuate rotation of bit 10 during boring ordrilling processes.

Bit 10 includes one or more optional grooves or flutes 28 that extendalong a portion 24 of a longitudinal length, indicated by line 26, fromwork end 20 towards tool end 18. Flutes 28 are generally defined as oneor more grooves that are separated by one or more lands 22 that alsoextend along body 14 of bit 10 in a direction away from cutting edge 12.Those skilled in the art will readily appreciate that flutes 28 andlands 22 are shaped and oriented to vent debris or swarf generatedduring a drilling or boring process from the hole being formed thereby.Although flutes 28 and lands 22 are shown as extending in a helicalmanner about portion 24 of body 14, it is appreciated that flutes 28 andlands 22 could extend at other helical pitch angles than that which isshown, be formed to extend in a generally linear or longitudinal manneralong body 14, or be omitted in other drilling or boring tools. It isfurther appreciated that the number of flutes 28 and lands 22, thelongitudinal component of the helical pattern, the thickness of flutes28 and lands 22, and the depth of flutes 28 could be provided in avariety of parameters and are preferably selected to satisfy, at leastin part, one or more parameters associated with the intended use of bit10.

Body 14 of bit 10 extends in a longitudinal direction along alongitudinal axis or centerline, indicated line 30, of body 14. Flutes28 and lands 22 are wound about centerline 30 and extend in alongitudinal direction, also indicated by line 26, along body 14. Body14 has a diameter, indicated by line 34, which can but need not beassociated with the size of a bore or hole intended to be formed by useof the respective bit 10. A resultant hole or bore is commonly definedby a diameter 34A associated with work end 20 associated with cuttingedge 12. Body 14 includes a radius proximate tool end 18, indicated bydimension line 36, which is defined as the distance between an outercircumferential edge 32 of body 14 and centerline 30 of the tool shankand a radius 36A associated with work end 20. It is appreciated thatbody 14 can be provided in a variety of diameters 34A to form differentsized holes associated therewith and that the shank portion of body 14need not be configured to pass through such a hole.

During the drilling or boring operation, bit 10 commonly rotates aboutcenterline 30 and is displaced in a longitudinal direction, indicated byarrow 40, to effectuate the formation of a bore or hole in a substrateor work material 42. It is appreciated that substrate or work material42 can have virtually any thickness and composition. In a preferredaspect of the present invention, drilling tools equipped with cuttingedge 12 have been shown to provide marked improvement of bore qualityand tool life when used with at least synthetic materials such as carbonor other fiber reinforced materials. It is appreciated that the sameattributes could be appreciated by users of virtually any materialcommonly worked with such boring tooling. That is, cutting edge 12 hasbeen shown to provide dramatically increased tool life with respect tovariety of comparably sized tools having cutting edges of differentshapes.

FIG. 2 shows a plan view of cutting edge 12 of bit 10 and FIG. 3 shows apartial view of only one radial side of cutting edge 12. Cutting edge 12includes a pair of alternate radial cutting portions 48, 50 that eachdefines a respective cutting edge 12 relative to the longitudinalcenterline of bit 10. The radial cutting portions 48, 50 are generallyseparated from one another by the axis associated with centerline 30.Alternate radial portions 48, 50 extend in opposite lateral or radiallyoutward or outboard directions, indicated by arrows 52, 54 (FIG. 3) fromcenterline 30. Each radial cutting portion 48, 50 includes a linearportion 56, 57 and a groove portion or curvilinear contour orcurvilinear portion 58, 59 that smoothly transition into one another,respectively, and, when considered collectively, extend the respectivecutting portion 48, 50 from centerline 30 to circumferential edge 32.Linear portions 56, 57 extend between a distal tip 60 of bit 10 and atransition zone 68, 69 associated with the intersection of therespective linear portion 56, 57 and corresponding curvilinear portion58, 59.

As explained further below with respect to FIGS. 2 and 3, cutting edge12 includes a first linear portion 56 and first curvilinear portion 58and a second linear portion 57 and a second curvilinear portion 59 thatdefine that shape of each respective cutting edge 12. As explainedfurther below, each respective cutting edge includes a deviation or achange in direction from the line associated with the cutting edge ofthe respective linear portion 56, 57. Each of the first respectivelinear and curvilinear shaped portion pair 56, 58 and the second linearand curvilinear shape portion pair 57, 59 extend from the centerline 30of bit 10 toward the circumferential edge 32 of the bit. It isappreciated that a bit having a different number of flutes 28 and lands22 could have a different number of linear and curvilinear shape pairs.

Referring to FIG. 3, the alternate radial linear portions 56, 57, or theportions of cutting edge 12 that are both linear and extend in a radial,outward, or outboard direction relative to centerline 30, are separatedfrom each other by an angle 62. Angle 62 is less than 180 degrees, isgreater than 60 degrees, and can preferably be about 120 degrees butother angles of separation can be provided for providing a more or lessaggressive angle of attack of cutting edge 12 as a function of thecomposition and/or hardness of material 42, intended operating speed ofbit 10, material of bit 10, and/or treatment of cutting edge 12. Such aconstruction also infers that each linear portion 56 is approximately 60degrees, indicated by angle 61, from centerline 30. It is furtherappreciated that each linear portion 56 has the same orientationrelative to centerline 30 to provide uniform rotational operation of bit10. However, it is appreciated that for bits having other numbers oflinear portions, such bits can be provided with linear portions that areformed at different angles relative to one another and/or differentangles relative to centerline 30.

Still referring to FIGS. 2 and 3, each curvilinear portion 58, 59extends from a first end 64, 65 that generally smoothly transitions fromthe respective linear portion 56, 57 to a second end 66, 67 thatlikewise smoothly transitions to a longitudinal radial outer edge 70 ofbody 14 of bit 10. Cutting edge 12 can include an optional radius 81that forms a curvilinear intersection between the correspondingcurvilinear portion 58, 59 and edge 70 of body 14. Preferably,curvilinear portion terminates radially inboard of radius 88 and extendsin a repeating manner between radius 88 transition zone 68, 69.Minimally, at least one deviation from the linear orientation of therespective linear shaped cutting edge is formed between the linearportion of the cutting edge and the outward radial or circumferentialedge of bit 10. As shown in FIG. 3, two deviations, or the shapesassociated with a number of valleys 76, 78, 80, 82 are provided betweenthe outer radial end of each respective linear portion of the cuttingedge and the outer radial shape of bit 10. Understandably, as explainedfurther below, more or fewer deviations may be provided in eachrespective radial portion of cutting edge 12.

As shown in FIGS. 2 and 3, each alternate radial curvilinear portion 58,59 of cutting edge 12 includes a number of valleys 76, 78, 80, 82 thatextend in a downward longitudinal direction towards tool end 18 of bit10. Each curvilinear portion 58, 59 of cutting edge 12 also includes anumber of curved ridges 84, 86, 88 that smoothly transition between theadjacent linear portion 56, 57, respective valleys 76, 78, 80, 82 andlongitudinal radial edge 70 or optional radius 81 of body 14 of bit 10.Such a construction provides a cutting edge 12 that forms a nonlinearcutting face wherein the only non-tangential directional change of thecutting surface is formed at distal tip 60 associated with work end 20at the interface between the linear portions 56, 57 on the oppositesides of centerline 30. Said in another way, adjacent locations alongcutting edge 12 are tangential to one another other than at thetransition across centerline 30 at the interface of the opposite linearportions 56, 57. Said in another way, each cutting tip 12 has acontinuous tangential shape that extends the entire length or diameterof the cutting tip on each opposite side of centerline 30. As is alsoshown in FIG. 3, each deviation associated with a respective curvilinearportion of the cutting edge that is nearer the longitudinal axis 30 ofbit 10 extends in a direction that is more aligned with the longitudinalaxis 30 than a second deviation or portion of the respective curvilinearshape that is nearer the outer circumferential edge 32 of bit 10 thanthe first portion and extends in a direction that more so approachesbeing perpendicular to longitudinal axis 30 than the radially interiororiented deviation.

Momentarily referring back to FIGS. 1 and 2, alternate grooves or flutes28 and lands 22 extend along a portion of the longitudinal length of bit10. As disclosed above, bits having other numbers of flutes and groovesare envisioned and within the scope of the appending claims. Alternateradial cutting-edge portions 90, 92 extend along the helicallongitudinal edge of each respective flute and land 22. It isappreciated that cutting-edge portions 90, 92 be shaped and orientedrelative to the diameter of cutting edge 12 to provide only limitedcutting or “dressing” of a respective hole or provided only a guidedinteraction of bit 10 with the sidewalls of the resultant hole formed bycutting edge 12 of bit 10. As explained further below with respect toFIGS. 4-6, it is envisioned that edge portions 90, 92 may provide such afinal dress cut to the resultant hole.

Referring back to FIGS. 2 and 3, as curvilinear portions 58, 59 ofcutting edge 12 traverse in a generally rearward rotational direction,or direction in opposite to the rotational direction indicated by arrow96, away from the cutting edge 12 of bit 10, the contour associated withthe linear portions 56, 57, valleys 76, 78, 80, 82, and curved portions84, 86, 88 regress or decline toward tool end 18 of bit 10. Such aconstruction reduces the undesired interaction between those portions ofbit 10 that are offset from cutting edge 12 toward tool end 18 of bit 10while maintaining enough structure of bit 10 proximate the cutting edge12 so as to effectuate the cutting process without undue downward force.Preferably, the contour of valleys 76, 78, 80, 82, and curved portions84, 86, 88 are tapered in the longitudinal direction toward tool end 18and rotationally oriented relative to a plane oriented perpendicular tothe longitudinal centerline 30 of bit 10.

Preferably, the channels associated with valleys 76, 78, 80, 82 areground into curvilinear portions 58, 59 of cutting edge 12 therebydeviating curvilinear portions 58, 59 from a substantially linear shape.Preferably, each land 22 includes a generally planar face that faces acorresponding flute 28. Such a configuration provides a smoothtransition from valleys 76, 78, 80, 82 into the space that extends alongthe longitudinal length of lands 22. Preferably, each valleys 76, 78,80, 82 has a length that is substantially nearer the widest width of therespective valleys 76, 78, 80, 82 than to a longitudinal length of bit10. Said in another way, although each valley 76, 78, 80, 82 extendsalong cutting edge 12 in a direction generally along the longitudinalshape of the respective land 22, such length is only a very smallportion of the overall length of the longitudinal length of therespective flute and corresponding 22.

FIGS. 4-6 show a bit 100 according to another embodiment of theinvention that also shows unexpected improvements with respect to itsusable life as well as a bore or hole quality. Like bit 10, bit 100includes an elongate body 102 that extends between a tool end 104 and awork end 106. Body 102 is defined by a shaft 108 that extends along alongitudinal axis or centerline 110 of bit 100. A number of lands 112,114 extend in a helical manner about a portion of bit 100. Lands 112,114 extend from a cutting edge 118 of bit 100 toward a shank portion 120of bit 100 and are separated by respective grooves or flutes 122, 124. Arotationally forward facing edge of each land 112, 114 is defined by acutting face 126, 128 that extends along the forward helical edge of therespective land 112, 114. The radially outward oriented face 130, 132 ofeach land 112, 114 includes a number of optional grooves 138, 140, 142,144 that are oriented rearward of the respective cutting edge 126, 128.Grooves 138 140, 142, 144 reduce drag associated with the rotationalmovement of the outer radial surface of lands 112, 114 past the materialassociated with the bore or hole formation.

As shown in FIGS. 5 and 6, like bit 10, cutting edge 118 of bit 100includes a first linear portion 152 and a second linear portion 154 thatextend in opposite generally radial directions relative to centerline110 of bit 100. Cutting edge 118 includes first and second curvilinearportions 156, 158 that extend in outward radial directions from eachlinear portion 152, 154 toward a first circumferential edge 160 of bit100. As alluded to above and as explained further below, bit 100includes a step 164 that provides a final transition between firstcircumferential edge 160 and a second or largest circumferential edge166 of bit 100. Circumferential edge 166 is defined by the outer radialedge associated with lands 112, 114 and the cutting-edge 126, 128associated therewith. Edges 160, 166 and step 164 allows that portion ofbit 100 that is radially inboard of step 164 to remove a majority of thematerial associated with a hole formed with bit 100 and such thatcutting edges 126, 128 and the radially forward facing portion of step164 provide a hole dressing and/or final cut associated with formationof a respective hole.

As shown in FIG. 6, each curvilinear portion 156, 158 includes one, ormore valleys 170, 172 and one or more ridges 174, 176, 178 that providefor a nonlinear but generally smooth transition between firstcircumferential edge 160 and the outer radial edge of the respectivelinear portion 152, 154 of bit 100. Like bit 10, linear portion 152includes a relief that extends rearward from the cutting edge associatedwith the linear portion thereof. Each linear portion 152, 154 of bit 100includes a first relief 180 and a second relief 182 that are tapered ina downward direction toward tool end 104 of bit 100. Reliefs 180, 182serve to reduce the amount of material of bit 100 that is rearward ofthe linear portion 152, 154 of cutting edge 118 that contacts thesubstrate material during a drilling operation due to the rotation ofbit 100 in an operating direction, indicated by arrow 186. Similarly, asgrooves or valleys 170, 172 and ridges 174, 176, 178 regress in arearward rotational direction, a rotational direction opposite direction186, valleys 170, 172 and ridges 174, 176, 178 translate in a downwardlongitudinal direction toward tool end 104 of bit 100, respectively, tolimit that portion of the end surface of the respective lands 112, 114that is rearward of the respective curvilinear portion 156, 158 ofcutting edge 118 which contacts the work material during the drillingoperation.

The substantially non-linear shape of the cutting edge associated withbits 10, 100 increases the cutting length associated with operation ofthe respective cutting tip to over 10% more than the cutting length of amaterial being worked or the entry pitch diameter of the hole beingformed. Accordingly the elongated length of the cutting edge provided bybits 10, 100 is believed to at least partly improve the operating lifeof the corresponding bit 10. It is perceived that the generally smoothcontinuous waveform of the curvilinear shape of the cutting edgeintroduces some benefits to the cutting process that cannot be achievedwith conventional drilling tools. The continuously changing shapeassociated with cutting edges 12, 118 appears to result in acontinuously changing shear angle of the point of interface or cut withthe material with respect to the radial direction associated with thecut. This change is believed to result in changing forces along the cutinterface and such interaction seemingly improves cutting action, maytend to reduce harmonics and/or tool chatter, reduce localizedtemperature concentrations during drilling processes, and may evencontribute to providing a smoother and/or quieter cut.

Although some prior art drill bits are provided with singular ormultiple straight line cutting edges that may be provided at differentangles relative to one another, the shape of cutting edges 12, 118displays highly unexpected results with respect to tool life and holequality allowing use of bit 10, 100 beyond the usable life of comparablysized and treated tools not equipped with cutting edge 12, 118,respectively. Simply put, bits 10, 100 have an operating life that isunexpectedly much longer than other comparable sized tools. As explainedfurther below, it is believed that the operating life of bits 10, 100can be even more improved with the use of optional coating materialsapplied to at least cutting edge 12, 118 and optionally along thelongitudinal helical edges of the one or more flutes and landsassociated therewith.

Although it is envisioned providing at least cutting edge 12, 118 of abit with a supplemental wear resistant treatment, such as one of ahoning operation, a shot peening process, a heat treating process, aquenching process, and/or applying a coating of a diamond based ordiamond coating or diamond like material or coating (DLC), or a physicalvapor deposition (PVD) coating, and preferably, applying at least onesuch treatment to both cutting edge 12, 118 and the longitudinal lengthof the outer radial edge of at least a portion of respective flutes andlands, the unexpected useful life benefits described above have beenobserved in bits without such supplemental treatment thereby evidencingthe beneficial performance of merely the shape of cutting edge 12, 118.Those skilled in the art will readily appreciate from applicant'sdisclosure that such treatment processes will further improve theoperating life of the resultant bit.

Cutting tips 12, 18 include a geometrically definable shape of the drillpoint or cutting tip at the distal end of a twist drill. Approximatelythe center radial third of cutting tip is a generally straight angledsection. It is appreciated that the angled section could be provided atvirtually any cutting angle that maintains a penetration vector althoughthe straight angled section is preferably provided between approximately105 degrees to 160 degrees from the longitudinal axis of the drill bit.It is also appreciated that the linear portion of the cutting edge canextend for different percentages such as greater than ⅛ of the total cutdiameter, less than ⅞ of total cut diameter, or any percentagetherebetween. As shown, the center radial third of cutting edge 12 ismaintained at about 60-180 degrees, or alternatively 90-150 degreesrelative to the longitudinal length of the opposite radial side linearportion of the cutting tip or relative to the longitudinal axis ofrespective drill bit 10, 100. Said in another way, the alternate radialportions of cutting edge 12, 118 can be separated by 40-18 degreesrelative to one and are more preferably separated by an angle oralternatively about 80-120 degrees relative to one another.

Radially outward of the radially outward oriented ends of the centerradial third of cutting edge 12, 118 and preferably in a substantiallytangential manner with respect to the longitudinal axis of therespective bit, cutting edge 12, 118 transitions into a series of pseudosine-wave contours that transition to the radial or at least nearcircumferential largest outer edge of the respective bit. Preferably,each geometric transition or directional change is smooth and providesno stepped discontinuity to the form of the cutting edge 12, 118 exceptat the transition between the alternate radial sides of the cutting edge12, 118 and which occurs at centerline 30, 110 of the respective bit 10,100. Preferably, cutting edge 12, 118, and the geometry thereof, isimparted on the drill point by grinding the form on the end associatedwith cutting edge 12, 118 of the bit but it is appreciated that othermeans of forming cutting edge 12, 118 are envisioned and, withconsideration of this disclosure, within the skill of those in the art.

Each of cutting edges 12, 118 has been shown to dramatically increasethe effective or operating life of bit 10, 100. That is, cutting edge12, 118 has been shown to substantially increase the number and qualityof holes a drill bit can produce prior to failure, independent of thedrill and work-piece material. That is, it is appreciated that cuttingedge 12, 118 can improve the hole quality and number of holes that canbe drilled through various materials including but not limited to metalbased materials such as aluminum, brass, carbon, and stainless steelsand alloys, cast materials, laminate and glass and/or fiber reinforcedmaterials such as boron or carbon fiber reinforced materials. It isappreciated that such materials, as well as the drilling of holes insuch materials, has applicability across a number of industriesincluding construction, automotive, and aircraft fabrication andmaintenance fields. It is believed that bits 10, 100 provide a desiredhole finish and bit life that exceeds the capabilities of any currentlyavailable and comparable sized product. It is further appreciated thatbits 10, 100 can be formed from any number of materials but ispreferably formed of a carbide tool material.

Although bits 10, 100 are shown in the figures as having a specificshape and configuration as indicated by the various dimensions discussedin reference to the figures, it is appreciated that bits 10, 100 couldhe provided in form factors of various drill bit diameters to providedifferent hole sizes, any number of waves provided on cutting edge 12,118 wave shapes having different wave frequencies and amplitudes, (whichwill affect the inherent wave radii), varied sizes associated with theoutside corner radius at the joining of the cutting tip with the outerdiameter of the drill bit, center portions with various angles andoperating lengths, alternate relative positions of the wave of thecutting tip relative to the centerline of drill bit, alternate numbersand depths of flute and land pairs along the longitudinal length of thedrill bit, etc. In a preferred aspect, the cutting tip of bits 10, 100has a generally smooth curvilinear shape wherein the only non-tangentialdirectional change to the edge associated with the cutting processoccurs at the centerline of the respective bit and between the linearinner radial portions of the respective cutting edge.

In a preferred aspect, the relative depths between the alternatecontours of the curvilinear portion of the respective cutting tip ispreferably between 1-4% of the total diameter of the respective bit andis preferably about 2.4% of the bit diameter. An outer circumferentialradius, such as the radius associated with outer radial ridges 81, 178,when provided, is preferably between 10-20% of the total bit diameterand preferably about or equal to 15% of the bit diameter. Preferably,the radius associated with each valley and ridge, such as valleys andridges 76, 78, 80, 82 84, 86, 170,172, 174, 176 is between about 5-15%of the bit diameter and is preferably about or equal to 9.5% of theoverall diameter. With respect to the ranges specified above and the useof the term about with respect to the same, it is appreciated that theterm “about” is the same as “approximately” and includes all of thediscrete percentage values within each respective range. It is furtherappreciated that although each of cutting edges 12, 118 are shown ashaving only two recesses or valleys along the radially oriented butlongitudinal length of the respective cutting edge, other numbers ofpositive and/or negative contours could be provided as the longitudinallength of the cutting edge as a function of the diameter of theresultant bit and the corresponding length of the respective linearsections of the respective cutting edges.

Therefore, one embodiment of the invention includes a drill bit orboring tool having a cutting edge that includes a pair of generallysmooth curvilinear shaped portions that are positioned near the radialouter portions of the cutting edge and connected to one another by apair of generally linear portions that traverse the longitudinalcenterline of the tool. A drill bit or boring tool having a cutting edgeor cutting tip having such a shape has been shown to provide improvedusable tool life while also reducing the undesirable effects of tearout, mushrooming, and heating of the work material throughout theuseable life of the boring tool.

Another embodiment of the invention includes a drill bit having a shaftthat extends along a longitudinal axis. The shaft includes a shank thatis engageable with a drive tool at one end of the shaft and a cuttingtip at an opposite end of the shaft. The cutting tip further comprisesat least two cutting edges that each extend in an outward radialdirection between the longitudinal axis of the shaft and an outercircumference of the shaft. Each cutting edge is tapered toward theshank as the cutting edge extends in an outward radial direction fromthe longitudinal axis. Each cutting edge includes at least one deviationfrom a linear shape. The at least one deviation has a curvilinear shapethat extends between the linear portion of the respective cutting edgeand an outer radial edge of the shaft.

Another embodiment of the invention includes a method of forming aboring tool. An elongate body is provided that extends along alongitudinal axis. The elongate body includes a first end that isconfigured to cooperate with a drive tool and a cutting point that isformed at a second end of the body opposite the first end. A firstlinear portion and a second linear portion are formed along a distaledge of the cutting point. The first linear portion and the secondlinear portion are formed on opposite sides of the longitudinal axis ofthe elongate body. A first curvilinear contour and a second curvilinearcontour are formed in the distal edge of the cutting point. Eachcurvilinear contour is offset in a radial direction from thelongitudinal axis of the elongated body and located radially outboard ofthe respective adjacent linear portion such that the only non-tangentialdiscontinuity of the cutting point occurs at a transition between thefirst linear portion and the second linear portion at the intersectionof the longitudinal axis.

Another embodiment of the invention includes a drill bit having anelongated body that extends between a tool end and a work end. A cuttingtip is formed at the work end of the drill bit. A first linear portionand a second linear portion are each formed on the cutting tip andintersect one another proximate a centerline of the elongated body. Eachlinear portion extends laterally across the cutting tip and is pitchedtoward the tool end of the elongate body as each respective linearportion extends in an outward radial direction from the centerline. Agroove portion is formed on each opposite lateral side of the cuttingtip. Each groove portion is located radially outboard of an adjacent oneof the first linear portion and the second linear portion and extendslaterally across the elongated body. Each groove portion is also pitchedtoward the shank end of the elongate body and terminates short of acircumferential radius of the elongated body. Each groove portion andcorresponding respective linear portion form a continuous tangentialshape that extends the entire length of the cutting tip on each oppositeside of the centerline.

The present invention has been described in terms of the preferredembodiment. The several embodiments disclosed herein are related asbeing related to the assembly as generally shown in the drawings. It isrecognized that equivalents, alternatives, and modifications, aside fromthose expressly stated, the embodiments summarized, or the embodimentshown in the drawings, are possible and within the scope of theappending claims. The appending claims cover all such alternatives andequivalents.

What is claimed is:
 1. A method of forming a boring tool comprising:providing an elongate body that extends along a longitudinal axis, theelongate body having a first end configured to cooperate with a drivetool and a cutting point formed at a second end of the elongate bodyopposite the first end; forming a first linear portion and a secondlinear portion along a distal edge of the cutting point, the firstlinear portion and the second linear portion being on opposite sides ofthe longitudinal axis; and forming a first curvilinear contour and asecond curvilinear contour in the distal edge of the cutting point, eachcurvilinear contour being offset in a radial direction from thelongitudinal axis of the elongate body and located radially outboard ofa respective first linear portion and the second linear portion, suchthat an only non-tangential discontinuity of the cutting point isdefined by a transition between the first linear portion and the secondlinear portion at an intersection of the longitudinal axis.
 2. Themethod of claim 1 further comprising twisting the elongate body to forma helix that extends along the elongate body and is defined by at leasttwo lands.
 3. The method of claim 2 further comprising forming at leastone groove in a radially outward facing surface between each of the atleast two lands.
 4. The method of claim 1 further comprising treatingthe cutting point for wear resistance after forming the at least onecurvilinear contour.
 5. The method of claim 4 wherein the treating isfurther defined as at least one of a honing operation, a shot peeningprocess, a heat treating process, a quenching process, a coatingprocess.
 6. The method of claim 4 wherein the treating is furtherdefined as a coating process that includes applying at least one of adiamond based material, a diamond like coating (DLC), and a PVD coatingto at least the cutting point of the boring tool.
 7. A method of forminga boring tool, the method comprising: providing an elongate body thatextends along a longitudinal axis that extends from a first end that isconfigured to cooperate with a drive tool to a second end that isopposite the first end; forming a cutting edge that is defined by thesecond end of the elongate body; and shaping the cutting edge to includea first linear portion and a second linear portion that extend inopposite outward radial directions relative to the longitudinal axis ofthe elongate body and a first curvilinear contour and a secondcurvilinear contour that are oriented radially outward of a respectiveone of the first linear portion and the second linear portion such thateach curvilinear contour is offset in a radial direction from thelongitudinal axis of the elongate body and located radially outboard ofa respective first linear portion and the second linear portion and eachof the first curvilinear portion and the second curvilinear portion havea similar shape relative to rotation of elongate body about thelongitudinal axis.
 8. The method of claim 7 further comprising formingat least two lands and at least two flutes that extend in a directiongenerally aligned with the longitudinal axis along at least a portion ofthe elongate body.
 9. The method of claim 8 further comprising formingthe at least two lands and at least two flutes to extend along theelongate body in at least one of a helical pattern and in a straightmanner.
 10. The method of claim 7 further comprising treating thecutting point for wear resistance after shaping of the first linearportion, the second linear portion, the first curvilinear contour, andthe second curvilinear contour.
 11. The method of claim 10 wherein thetreating is further defined as at least one of a honing operation, ashot peening process, a heat treating process, a quenching process, acoating process.
 12. The method of claim 10 wherein the treating isfurther defined as a coating process that includes applying at least oneof a diamond based material, a diamond like coating (DLC), and a PVDcoating to at least the cutting point of the boring tool.
 13. The methodof claim 7 wherein shaping the cutting edge further comprises taperingeach of the first curvilinear contour and the second curvilinear contourin a direction toward the first end of the elongate body as therespective curvilinear contour progresses toward a radial edge of theelongate body.
 14. The method of claim 7 further comprising shaping eachof the first curvilinear contour and the second curvilinear contour toinclude a plurality of deviations and shaping a respective deviationthat is nearer the longitudinal axis to extend in a direction that ismore aligned with the longitudinal axis than another deviationassociated with the respective curvilinear contour that is nearer acircumferential edge of the elongate body.
 15. The method of claim 7further comprising forming a step at a radially outboard surfaceproximate the second end of the elongate body.
 16. The method of claim15 further comprising offsetting the step toward the first end relativeto the cutting edge of the elongate body.